WO2016094665A1 - Procédé de production de boehmite cristalline nanométrique - Google Patents
Procédé de production de boehmite cristalline nanométrique Download PDFInfo
- Publication number
- WO2016094665A1 WO2016094665A1 PCT/US2015/065011 US2015065011W WO2016094665A1 WO 2016094665 A1 WO2016094665 A1 WO 2016094665A1 US 2015065011 W US2015065011 W US 2015065011W WO 2016094665 A1 WO2016094665 A1 WO 2016094665A1
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- WIPO (PCT)
- Prior art keywords
- slurry
- crystalline boehmite
- nanometers
- resin
- particle size
- Prior art date
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- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 title claims abstract description 98
- 229910001593 boehmite Inorganic materials 0.000 title claims abstract description 97
- 238000000034 method Methods 0.000 title claims abstract description 67
- 239000002245 particle Substances 0.000 claims abstract description 51
- 239000002002 slurry Substances 0.000 claims abstract description 40
- 239000000203 mixture Substances 0.000 claims abstract description 27
- 239000003063 flame retardant Substances 0.000 claims abstract description 24
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229920003023 plastic Polymers 0.000 claims abstract description 20
- 239000004033 plastic Substances 0.000 claims abstract description 20
- 239000002270 dispersing agent Substances 0.000 claims abstract description 19
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000002131 composite material Substances 0.000 claims abstract description 11
- 238000002156 mixing Methods 0.000 claims abstract description 11
- 239000002243 precursor Substances 0.000 claims abstract description 10
- 239000000088 plastic resin Substances 0.000 claims abstract description 9
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims abstract description 8
- 238000003672 processing method Methods 0.000 claims abstract description 6
- 238000001035 drying Methods 0.000 claims abstract description 4
- 238000010438 heat treatment Methods 0.000 claims abstract description 4
- 229910001679 gibbsite Inorganic materials 0.000 claims description 16
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 13
- 229920001577 copolymer Polymers 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 8
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 7
- 229920000728 polyester Polymers 0.000 claims description 7
- 229920005989 resin Polymers 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 6
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 4
- 239000004952 Polyamide Substances 0.000 claims description 4
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 4
- 239000011707 mineral Substances 0.000 claims description 4
- 150000007522 mineralic acids Chemical class 0.000 claims description 4
- 150000007524 organic acids Chemical class 0.000 claims description 4
- 229920002647 polyamide Polymers 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- 150000003839 salts Chemical class 0.000 claims description 4
- 239000004634 thermosetting polymer Substances 0.000 claims description 4
- 239000004640 Melamine resin Substances 0.000 claims description 3
- 229920000877 Melamine resin Polymers 0.000 claims description 3
- 239000004642 Polyimide Substances 0.000 claims description 3
- 229920002125 Sokalan® Polymers 0.000 claims description 3
- 125000003118 aryl group Chemical group 0.000 claims description 3
- 238000013329 compounding Methods 0.000 claims description 3
- 239000003822 epoxy resin Substances 0.000 claims description 3
- 238000001125 extrusion Methods 0.000 claims description 3
- 238000000465 moulding Methods 0.000 claims description 3
- 239000005011 phenolic resin Substances 0.000 claims description 3
- 239000004584 polyacrylic acid Substances 0.000 claims description 3
- 229920001721 polyimide Polymers 0.000 claims description 3
- 229920005672 polyolefin resin Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920005749 polyurethane resin Polymers 0.000 claims description 3
- 229920005992 thermoplastic resin Polymers 0.000 claims description 3
- 229920006337 unsaturated polyester resin Polymers 0.000 claims description 3
- 229920001567 vinyl ester resin Polymers 0.000 claims description 3
- 229920001169 thermoplastic Polymers 0.000 claims description 2
- 239000004416 thermosoftening plastic Substances 0.000 claims description 2
- 230000001747 exhibiting effect Effects 0.000 claims 1
- 239000000047 product Substances 0.000 description 41
- 238000002441 X-ray diffraction Methods 0.000 description 20
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 15
- 238000003801 milling Methods 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 9
- -1 for example Polymers 0.000 description 9
- 238000001000 micrograph Methods 0.000 description 8
- 238000001228 spectrum Methods 0.000 description 8
- 239000013078 crystal Substances 0.000 description 7
- 239000012467 final product Substances 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 6
- 238000007796 conventional method Methods 0.000 description 6
- 229920000058 polyacrylate Polymers 0.000 description 6
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 5
- 238000000227 grinding Methods 0.000 description 5
- 238000009826 distribution Methods 0.000 description 4
- 238000003756 stirring Methods 0.000 description 4
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N Nitric oxide Chemical compound O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 238000011161 development Methods 0.000 description 3
- 230000018109 developmental process Effects 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- 229920002943 EPDM rubber Polymers 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- 229920002292 Nylon 6 Polymers 0.000 description 2
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 2
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 2
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 2
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 2
- 150000005827 chlorofluoro hydrocarbons Chemical class 0.000 description 2
- 238000002425 crystallisation Methods 0.000 description 2
- 230000008025 crystallization Effects 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 238000010335 hydrothermal treatment Methods 0.000 description 2
- 238000006386 neutralization reaction Methods 0.000 description 2
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 2
- 229920002379 silicone rubber Polymers 0.000 description 2
- NNMHYFLPFNGQFZ-UHFFFAOYSA-M sodium polyacrylate Chemical compound [Na+].[O-]C(=O)C=C NNMHYFLPFNGQFZ-UHFFFAOYSA-M 0.000 description 2
- 239000012815 thermoplastic material Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- BNGXYYYYKUGPPF-UHFFFAOYSA-M (3-methylphenyl)methyl-triphenylphosphanium;chloride Chemical compound [Cl-].CC1=CC=CC(C[P+](C=2C=CC=CC=2)(C=2C=CC=CC=2)C=2C=CC=CC=2)=C1 BNGXYYYYKUGPPF-UHFFFAOYSA-M 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- 239000004716 Ethylene/acrylic acid copolymer Substances 0.000 description 1
- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 1
- 229920000299 Nylon 12 Polymers 0.000 description 1
- 229920003189 Nylon 4,6 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- 229920000331 Polyhydroxybutyrate Polymers 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- ZXRRHFSTAFVGOC-UHFFFAOYSA-N [AlH3].[K] Chemical compound [AlH3].[K] ZXRRHFSTAFVGOC-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 238000007563 acoustic spectroscopy Methods 0.000 description 1
- HGINCPLSRVDWNT-UHFFFAOYSA-N acrylaldehyde Natural products C=CC=O HGINCPLSRVDWNT-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000003463 adsorbent Substances 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 238000005465 air elutriation analysis Methods 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 150000004645 aluminates Chemical class 0.000 description 1
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 description 1
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical compound [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 description 1
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000000084 colloidal system Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 238000007559 electroresistance counting method Methods 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 229920005676 ethylene-propylene block copolymer Polymers 0.000 description 1
- 229920005674 ethylene-propylene random copolymer Polymers 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 150000004677 hydrates Chemical class 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000010902 jet-milling Methods 0.000 description 1
- 238000007561 laser diffraction method Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000012764 mineral filler Substances 0.000 description 1
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 238000007558 optical counting method Methods 0.000 description 1
- 238000007557 optical granulometry Methods 0.000 description 1
- 235000012771 pancakes Nutrition 0.000 description 1
- 238000002161 passivation Methods 0.000 description 1
- 239000005015 poly(hydroxybutyrate) Substances 0.000 description 1
- 229920001495 poly(sodium acrylate) polymer Polymers 0.000 description 1
- 229920001083 polybutene Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 229920005614 potassium polyacrylate Polymers 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 229920005675 propylene-butene random copolymer Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000007560 sedimentation technique Methods 0.000 description 1
- 238000005029 sieve analysis Methods 0.000 description 1
- 229940047670 sodium acrylate Drugs 0.000 description 1
- 229910001388 sodium aluminate Inorganic materials 0.000 description 1
- 238000004611 spectroscopical analysis Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F7/00—Compounds of aluminium
- C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
- C01F7/44—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water
- C01F7/447—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water by wet processes
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F7/00—Compounds of aluminium
- C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
- C01F7/44—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water
- C01F7/447—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water by wet processes
- C01F7/448—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water by wet processes using superatmospheric pressure, e.g. hydrothermal conversion of gibbsite into boehmite
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/016—Flame-proofing or flame-retarding additives
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2002/00—Crystal-structural characteristics
- C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
- C01P2002/72—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by d-values or two theta-values, e.g. as X-ray diagram
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/62—Submicrometer sized, i.e. from 0.1-1 micrometer
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2227—Oxides; Hydroxides of metals of aluminium
Definitions
- This disclosure relates generally to a process for producing alumina hydrates, also known as Boehmite. More specifically, this disclosure relates to a method of forming nano-scale crystalline Boehmite.
- Engineered plastic formulations have become commonly used in many applications, such as switches, sockets, connectors, fuse boxes, and manifold covers among others, that require the presence of one or more enhanced performance properties. These performance properties often include high impact strength, high durability, flame retardancy, low abrasion, high resistivity towards oil and other aggressive media, high thermal resistance, and/or electrical resistance.
- plastic resins for example, polyamides, epoxies, and polyesters, are compounded with glass fibers and various other additives specifically designed for use in an injection molding process.
- Boehmite aluminum oxide hydroxide
- Boehmite may also be combined with phosphorous-containing and nitrogen-containing flame retardants to provide the desired result.
- the average particle size (d 50 ) for the crystalline Boehmite is on the order of 7,000 nanometers (7.0 micrometers) or less.
- Boehmite Several methods that can be used to produce Boehmite include (i) the hydrothermal treatment of aluminum trihydroxide or Gibbsite (i.e., AI 2 0 3 -3H 2 0) at high temperature (200°-250°C) and steam pressure; (ii) neutralization of aqueous solutions of aluminum salts, such as aluminum chloride, aluminum sulfate and aluminum nitrate, by alkalis, such as NaOH, KOH and NH 4 OH; (III) neutralization of aluminates, such as sodium aluminate, by an acid (e.g., HCI or H 2 S0 4 ) or carbon monoxide; or (iv) hydrolysis of organic aluminum compounds, such as aluminum alkylates.
- aluminum trihydroxide or Gibbsite i.e., AI 2 0 3 -3H 2 0
- alkalis such as NaOH, KOH and NH 4 OH
- aluminates such as sodium aluminate
- the present disclosure generally provides method of forming a crystalline Boehmite product.
- This method comprises preparing an aqueous slurry by mixing together water, large aluminum oxide precursors, a highly dispersible Boehmite grade, and optionally, a dispersing agent; adjusting the pH of the slurry to be between about 8.0 to about 12.0; heating the slurry to a temperature between 120°C and 250°C for a duration of time that is from about 1 .0 hour up to about 24 hours; collecting the slurry to form a wet cake; and drying the wet cake to obtain the crystalline Boehmite product.
- the crystalline Boehmite product formed using this method exhibits an average particle size (d 50 ) that is less than 7,000 nanometers.
- the method may further include the use of a dispersing agent, including but not limited to an organic dispersant.
- This organic dispersant may include without limitation, an acrylic or polyacrylic acid, a salt of acrylic acid, an acrylates copolymer, or a mixture thereof.
- a crystalline Boehmite product is provided that is formed according to the process described above and further defined herein.
- the pH of the slurry is adjusted to be between about 10.0 and about 12.0.
- the slurry may be heated to a temperature between about 170°C to about 220°C, alternatively, about 180°C.
- the time duration in which the slurry is heated may range between about 1 hour and about 10 hours; alternatively, between about 2 hours and about 5 hours.
- the crystalline Boehmite product that is formed exhibits an average particle size (d 50 ) that is greater than about 100 nanometers and less than about 3,000 nanometers. Alternatively, the crystalline Boehmite product exhibits an average particle size between about 500 nanometers and 2,000 nanometers.
- the crystalline Boehmite product may further comprise a crystallite size that is between about 30 nanometers to about 120 nanometers.
- the highly dispersible Boehmite can act as a seed material.
- the highly dispersible Boehmite may exhibit a particle size that is less than 100 nm and can be formed using heat and/or shear with concentrations of 0.5% to 7.5% mineral or organic acid relative to the alumina content.
- the large aluminum oxide precursors exhibit an average particle size (d 50 ) of about 50 micrometers or more.
- the large aluminum oxide precursors may be a coarse grade Gibbsite.
- a method of forming a flame retardant composite comprises forming a crystalline Boehmite product according to the process described above and herein that exhibits an average particle size (d 50 ) that is less than 7,000 nanometers; mixing the crystalline Boehmite product with a plastic resin to form a flame retardant plastic mixture; and subjecting the flame retardant plastic mixture to a conventional plastic processing method to form a flame retardant composite.
- the plastic resin may be selected as either a thermoplastic or a thermoset resin.
- the thermoplastic resin may be selected as one from the group of olefin resins, aromatic polyesters, polyesters, and polyamides.
- the thermoset resin may be selected as one from the group of an epoxy resin, vinyl ester resin, phenol resin, unsaturated polyester resin, polyimide, polyurethane, and melamine resin.
- the plastic resin may be processed using any conventional methodology, such as compounding, extrusion, or molding.
- Figure 1 is a schematic representation of a method of forming a crystalline Boehmite product according to the teachings of the present disclosure
- Figure 2 is a schematic representation of a method of forming a flame retardant composite utilizing the crystalline Boehmite product formed according to the method of Figure 1 ;
- Figure 3A is a photomicrograph of a crystalline Boehmite product formed according to the teachings of the present disclosure
- Figure 3B is a x-ray diffraction pattern measured for the crystalline Boehmite product shown in Figure 3A;
- Figure 4A is a photomicrograph of a comparative crystalline Boehmite product formed according to a conventional method
- Figure 4B is a x-ray diffraction pattern measured for the comparative crystalline Boehmite product shown in Figure 4A;
- Figure 5A is a photomicrograph of a comparative crystalline Boehmite product formed according to another conventional method
- Figure 5B is a x-ray diffraction pattern measured for the comparative crystalline Boehmite product shown in Figure 5A;
- Figure 6A is a photomicrograph of a comparative crystalline Boehmite product formed according to yet another conventional method;
- Figure 6B is a x-ray diffraction pattern measured for the comparative crystalline Boehmite product shown in Figure 6A.
- the present disclosure generally relates to the formation of crystalline Boehmite having an average particle size (d 50 ) that is 7.0 micrometers or less, alternatively less than about 3.0 micrometers.
- d 50 average particle size
- the Boehmite made and used according to the teachings contained herein is described throughout the present disclosure in conjunction with its use as a flame retardant in order to more fully illustrate the concept.
- the incorporation and use of Boehmite formed according to the process described herein in other applications is contemplated to be within the scope of the disclosure.
- Boehmite is generally used to describe an alumina hydrate that exhibits an x-ray diffraction (XRD) pattern that is similar to aluminum oxide-hydroxide, AIO(OH).
- Boehmite may contain various amounts of water of hydration and may, therefore, exhibit a range in surface area, pore volume, and specific density, as well as thermal characteristics upon thermal treatment. The degree of crystallinity, crystal size, and amount of imperfections in the Boehmite can be determined by the sharpness and location of the peaks within the measured XRD pattern.
- Boehmite may be utilized as ceramic materials, abrasive materials, retardants, adsorbents, fillers in composites, and catalysts, such as those used in refinery operations, for hydro-processing hydrocarbon feeds, for pollution control, hydrocarbon cracking, the production of ethylene oxide or methanol, the conversion of chlorofluorohydrocarbons (CFCs), and the reduction of nitrogen oxide from exhaust gases of gas turbines.
- the method 1 generally comprises preparing 10 an aqueous slurry by mixing together water, a coarse grade Gibbsite, a highly dispersible Boehmite grade to act as a seed material, and optionally, a dispersing agent; adjusting 15 the pH of the slurry; heating 20 the slurry; collecting 25 the slurry to form a wet cake; drying 30 the wet cake to obtain the crystalline Boehmite product, wherein the crystalline Boehmite product exhibits an average particle size (d 50 ) that is less than about 7,000 nanometers (7.0 micrometers).
- the pH of the slurry is adjusted 15 to be between about 8.0 to about 12.0; alternatively, between about 10.0 and about 12.0; alternatively, about 1 1 .0.
- the slurry is heated 20 to a temperature between 120°C and 250°C for a time duration that is from about 1 hour up to about 24 hours.
- the slurry is heated 20 to a temperature between about 170°C to 220°C; alternatively, about 180°C.
- the time duration during which the slurry is heated 20 may alternatively be between about 1 hour and about 10 hours; alternatively, between about 2 hours and about 5 hours.
- the pH and the temperature of the slurry represent features in the preparation of the crystalline Boehmite product that affect the rate of crystallization that occurs for the Boehmite. More specifically, the crystallization rate increases with both an increase in pH and/or temperature. In other words, the higher the pH and/or temperature utilized in the process, the greater the potential for forming crystalline Boehmite.
- the average particle size, D 50 is defined as the median diameter or medium value of particle diameter by mass and is usually expressed in nanometers (nm) or micrometers ( ⁇ ).
- a measurement of D 50 for a Boehmite product may be obtained by any method known to one skilled in the art, including without limitation sieve analysis, air elutriation analysis, photoanalysis, optical counting methods, electroresistance counting methods, sedimentation techniques, laser diffraction methods, and acoustic spectroscopy.
- the crystalline Boehmite product formed by the method 1 of the present disclosure exhibits an average particle size (d 50 ) that is less than about 7,000 nanometers (7.0 micrometers).
- the average particle size (d 5 o) is greater than about 100 nanometers and less than about 3,000 nanometers; alternatively between about 500 nanometers and 2,000 nanometers.
- the crystalline Boehmite product further comprises a crystallite size that is between about 20 nanometers to about 150 nanometers; alternatively, between about 30 nanometers to about 120 nanometers; alternatively, between about 50 nanometers to about 100 nanometers.
- the crystallite size can measured utilizing x-ray diffraction (XRD) spectroscopy.
- XRD x-ray diffraction
- One example of an instrument capable of measuring the crystallite size is a Rigaku Miniflex 2 benchtop XRD spectrometer. The crystallite size is obtained by measuring the peak at the 021 reflections and then calculated using the Scherrer equation not accounting for any background or peak fitting.
- the small average particle size (d 50 ) exhibited by the crystalline Boehmite product formed according to the teachings of the present disclosure is beneficial to reducing the overall cost of the product when used in an application that requires a small particle size, such as for example, flame retardants and metal passivation.
- Conventional processes for forming crystalline Boehmite typically result in an average particle size (d 5 o) that is greater than about 50 micrometers and require additional processing steps, such as milling.
- milling is defined as any known process or technique that results in a reduction in the average particle size (d 50 ) exhibited by the alumina product. Examples of techniques that are used in such milling processes include ball or attritor mills, jet mills, high-shear mixers, and colloid mixers to name a few.
- the method of producing crystal Boehmite uses large aluminum oxide precursors that exhibit an average particle size (d 50 ) that is about 50 micrometers or larger.
- These large aluminum precursors may be a coarse grade Gibbsite, such as that commonly found to exist with many commercial Gibbsite.
- commercial gibbsite include hydrated alumina or aluminum hydroxide, e.g., C-30 (Alcoa World Alumina LLC, Pittsburgh, PA) and GB/T 4294-2010 (Aluminum Corporation of China Ltd. or CHALCO, Beijing, China), among others.
- the highly dispersible Boehmite acts as a seed material in the slurry.
- This highly dispersible Bohemite is the Alumax PB-950 product manufactured by Pacific Industrial Development Corporation, Ann Arbor, Michigan.
- Highly dispersible Boehmite may be prepared via a precipitation process and can be defined as having greater than 95% of the product being readily dispersed to particles less than 100 nm using heat and/or shear in the presence of a small amount of mineral or organic acid.
- the heat and/or shear provided by the hydrothermal treatment may also act to disperse the Boehmite and provide an initial seed material.
- the amount of mineral or organic acid may be in the range of about 0.5% to about 7.5% weight of the entire weight of the dispersion.
- the process for forming the crystalline Boehmite product may include the use of a dispersing agent or surfactant as part of the slurry that is created.
- the dispersing agent is an organic dispersant.
- This organic dispersant may be without limitation, an acrylic or polyacrylic acid, a salt of acrylic acid, an acrylates copolymer, or a mixture thereof.
- salts of acrylic acid include ammonium polyacrylate, potassium aluminum polyacrylate, potassium polyacrylate, and sodium polyacrylate, among others.
- acrylates copolymers include, but are not limited to, ammonium acrylates copolymers, ethylene/acrylic acid copolymers, ethylene/sodium acrylate copolymers, acrylates/ammonium methacrylate copolymers, styrene/acrylates copolymers, acrylates/hydroxyesters acrylates copolymers, ethylene/methacrylate copolymers, and sodium acrylates/acrolein copolymers.
- water may be added in the range of 60% up to 90% relative to the overall weight of the slurry
- the seed material can be added in the ratio from 0.05 to 0.25 to coarse grade gibbsite
- the coarse grade gibbsite can be added from 10% to 30% relative to the overall weight of the slurry
- the optional dispersant can be added from 0.001 % up to 0.02% relative to the overall weight of the slurry.
- the crystalline Boehmite product prepared according to the teachings of the present disclosure can be used to provide mechanical durability and flame retardancy to various types of plastic composites, such as printed circuit boards and cable jacketing to name a few.
- Boehmite lends itself to this type of application because it does not begin to thermally decompose until it reaches a temperature of about 340°C as shown in Equation 1.
- the use of Boehmite as a flame retardant is of relevance whenever the temperature encountered during the processing of the plastic exceeds 200°C or when end-use applications need to pass prolonged ageing tests conducted at elevated temperatures.
- the plastic composites may include thermoplastic materials or thermoset materials without limitation.
- thermoplastic materials include, but are not limited to, blends of polyethylene (PE) and ethylene-vinylacetate-copolymers and elastomers like ethylene-propylene-diene-monomers (EPDM) and silicone rubbers (SR).
- thermoplastic resin examples include, without limitation, olefin resins, such as, olefin homopolymers (e.g., polyethylene, polypropylene, and polybutene) and olefin copolymers (e.g., ethylene-propylene random copolymers, ethylene-propylene block copolymers, propylene-butene random copolymers, propylene-butene block copolymers, and ethylene-propylene-butene copolymers); aromatic polyesters, such as polyethylene terephthalate and polybutylene terephthalate; polyesters, such as polycaprolactam and polyhydroxybutyrate; and polyamides, such as nylon-6, nylon-66, nylon- 10, nylon- 12 and nylon-46.
- olefin resins such as, olefin homopolymers (e.g., polyethylene, polypropylene, and polybutene) and olefin copolymers (e.g.,
- thermosetting resin examples include, without limitation, epoxy resin, vinyl ester resin, phenol resin, unsaturated polyester resin, polyimide, polyurethane, and melamine resin.
- the amount of the gibbsite type aluminum hydroxide particles to be filled is usually about from 30 to 150 parts by mass per 100 parts by mass of the resin. Additional information may be obtained in U.S. Patent Publication No. 2007/01 16641 , the entire contents of which are hereby incorporated by reference.
- a method 100 for forming a flame retardant composite comprises preparing 1 10 a crystalline Boehmite product according the teachings of the present disclosure followed by mixing 1 15 said product with a plastic resin to form a flame retardant plastic mixture. This flame retardant plastic mixture is then subjected to a conventional plastic processing method to form a flame retardant composite.
- conventional plastic processing methods include compounding, extrusion, and molding, without limitation.
- Example 1 Method of Forming Crystalline Boehmite Product
- a total of 700 grams of deionized (Dl) water is combined with 0.03 grams of ammonium polyacrylate as a dispersing agent under mixing conditions.
- a total of 270 grams of Gibbsite (coarse grade alumina) and 30 grams of a highly dispersible Boehmite (Alumax PB-950, Pacific Industrial Development Corporation, Ann Arbor, Michigan) is added to the water and dispersing agent to form a slurry.
- the slurry is mixed for 15 minutes to ensure homogeneity.
- the acidity/basicity of the slurry is then adjusted to a pH of 1 1.0 using sodium hydroxide crystals.
- the slurry is placed into a Parr 2-liter autoclave and heated to a temperature of 180°C for the duration of 1.5 hours with continued stirring of the slurry at a speed of 200 rpm.
- the slurry is then removed and filtered to obtain a wet cake, which is then dried at 120°C overnight (about 12-14 hours).
- the final product is verified by x-ray diffraction (XRD) to be crystalline Boehmite as shown in the micrograph of Figure 3A and XRD spectrum of Figure 3B.
- the crystalline Boehmite is verified in the XRD spectrum as the peaks at the reflections 020 and 021.
- the micrograph shows an agglomerate of submicron particles ( ⁇ 800 nm).
- the resulting particle distribution is also measured using a Horiba LA920WET with the average particle size (d 50 ) being determined to be 1 ,300 nanometers.
- the crystalline Boehmite formed in this example is suitable for use in applications without having to introduce a milling or grinding step to further reduce the average particle size.
- This example demonstrates the formation of a crystalline Boehmite product according to the present disclosure without having to grind or mill the raw material or product to have the crystalline Boehmite exhibit an average particle size (d 5 o) that is suitable for use as a flame retardant
- Example 2 Comparative Example A.
- a total of 700 grams of deionized (Dl) water is combined with 0.03 grams of ammonium polyacrylate under mixing conditions.
- a total of 300 grams of Gibbsite (coarse grade alumina) is added to the water and dispersing agent and mixed for 15 minutes to ensure homogeneity.
- the acidity/basicity of the mixture is then adjusted to a pH of 1 1 .0 using sodium hydroxide crystals.
- the mixture is placed into a Parr 2-liter autoclave and heated to a temperature of 180°C for the duration of 1 .5 hours with continued stirring of the mixture at a speed of 200 rpm.
- the mixture is then removed and filtered to obtain a wet cake, which is then dried at 120°C overnight (about 12-14 hours).
- the final product is verified by x-ray diffraction (XRD) to be crystalline Boehmite as shown in the micrograph of Figure 4A and XRD spectrum of Figure 4B.
- the crystalline Boehmite is verified in the XRD spectrum as the peaks at the reflections 020 and 021 .
- the micrograph shows larger crystalline particles greater than 5 microns in size.
- the resulting particle distribution is also measured using a Horiba LA920WET with the average particle size (d 50 ) being determined to be 75,000 nanometers.
- the crystalline Boehmite formed in this example is too large for use in applications without having to introduce a milling or grinding steps to further reduce the average particle size.
- This example demonstrates the formation of a crystalline Boehmite product according to a conventional method exhibits an average particle size (d 50 ) that is not suitable for use as a flame retardant without being subjected to additional milling processes.
- a total of 700 grams of deionized (Dl) water is combined with 0.03 grams of ammonium polyacrylate under mixing conditions.
- a total of 300 grams of Gibbsite (jet milled alumina) is added to the water and dispersing agent and mixed for 15 minutes to ensure homogeneity.
- the Gibbsite (coarse grade alumina) of Example 1 or 2 which has an average particle size (d 50 ) of about 75,000 nanometers, is subjected to milling prior to being added to the mixture by using a pancake style Hosakawa jet mill. This milling or grinding process resulted in reducing the average particle size (d 50 ) of the Gibbsite starting material to 2,000 nanometers.
- the acidity/basicity of the mixture is then adjusted to a pH of 1 1 .0 using sodium hydroxide crystals.
- the mixture is placed into a Parr 2-liter autoclave and heated to a temperature of 180°C for the duration of 1 .5 hours with continued stirring of the mixture at a speed of 200 rpm.
- the mixture is then removed and filtered to obtain a wet cake, which is then dried at 120°C overnight (about 12-14 hours).
- the final product is verified by x-ray diffraction (XRD) to be crystalline Boehmite as shown in the micrograph of Figure 5A and XRD spectrum of Figure 5B.
- the crystalline Boehmite is verified in the XRD spectrum as the peaks at the reflections 020 and 021 .
- the micrograph shows an agglomerate of submicron particles ( ⁇ 1000 nm).
- the resulting particle distribution is also measured using a Horiba LA920WET with the average particle size (d 50 ) being determined to be 7,500 nanometers.
- the crystalline Boehmite formed in this example is too large for use in applications without having to introduce an additional milling or grinding step to further reduce the average particle size of the final product.
- This example demonstrates the formation of a crystalline Boehmite product according to another conventional method exhibits an average particle size (d 50 ) that is not suitable for use as a flame retardant without being subjected to additional milling processes.
- a total of 700 grams of deionized (Dl) water is combined with 0.03 grams of ammonium polyacrylate under mixing conditions.
- a total of 300 grams of Gibbsite (coarse grade alumina) and 30 grams of the crystal Boehmite from Example 1 is added to the water and dispersing agent and mixed for 15 minutes to ensure homogeneity.
- the acidity/basicity of the mixture is then adjusted to a pH of 1 1 .0 using sodium hydroxide crystals.
- the mixture is placed into a Parr 2-liter autoclave and heated to a temperature of 180°C for the duration of 1 .5 hours with continued stirring of the mixture at a speed of 200 rpm.
- the mixture is then removed and filtered to obtain a wet cake, which was then dried at 120°C overnight (about 12-14 hours).
- the final product is verified by x-ray diffraction (XRD) to be crystalline Boehmite as shown in the micrograph of Figure 6A and XRD spectrum of Figure 6B.
- the crystalline Boehmite is verified in the XRD spectrum as the peaks at the reflections 020 and 021 .
- the micrograph shows particle with a size greater than about 6,000 nm.
- the resulting particle distribution is also measured using a Horiba LA920WET with the average particle size (d 50 ) being determined to be 6,000 nanometers.
- the crystalline Boehmite formed in this example is too large for use in applications without having to introduce an additional grinding step to further reduce the average particle size of the final product.
- This example demonstrates the formation of a crystalline Boehmite product according to yet another conventional method exhibits an average particle size (d 50 ) that is not suitable for use as a flame retardant without being subjected to additional milling processes.
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Abstract
La présente invention concerne un produit de boehmite cristalline et un procédé de formation dudit produit dans lequel la boehmite cristalline présente une taille moyenne (d50) de particules qui est inférieure à 7 000 nanomètres. Ce procédé consiste à préparer une suspension épaisse aqueuse en mélangeant ensemble de l'eau, des précurseurs d'oxyde d'aluminium de grande taille, une qualité de boehmite hautement dispersible, et éventuellement, un agent dispersant organique; à ajuster le pH de la suspension épaisse; à chauffer la suspension épaisse pendant une durée prédéfinie; à récupérer la suspension épaisse pour former un gâteau humide; et à sécher le gâteau humide pour obtenir le produit de boehmite cristalline. Le produit de boehmite cristalline peut être mélangé avec une résine plastique pour former un mélange plastique ignifugé, qui peut être soumis à un procédé de traitement de plastique classique pour former un composite ignifugé.
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EP15825689.1A EP3230209A1 (fr) | 2014-12-11 | 2015-12-10 | Procédé de production de boehmite cristalline nanométrique |
US15/534,146 US10344140B2 (en) | 2014-12-11 | 2015-12-10 | Process for producing nano-scale crystalline boehmite |
JP2017531265A JP2018503583A (ja) | 2014-12-11 | 2015-12-10 | ナノスケールの結晶性ベーマイトを製造するための方法 |
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RU2674952C1 (ru) * | 2017-12-27 | 2018-12-13 | Федеральное государственное бюджетное учреждение науки Институт физики прочности и материаловедения Сибирского отделения Российской академии наук (ИФПМ СО РАН) | Способ получения микро-мезопористых наноматериалов на основе складчатых нанолистов оксигидроксида алюминия и материал, полученный данным способом |
JPWO2018198650A1 (ja) * | 2017-04-25 | 2019-11-07 | 神島化学工業株式会社 | アルミナ水和物粒子、難燃剤、樹脂組成物及び電線・ケーブル |
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TWI670365B (zh) * | 2018-03-14 | 2019-09-01 | Taiwan Textile Research Institute | 阻燃塑膠粒及阻燃片材 |
CN109065810A (zh) * | 2018-08-15 | 2018-12-21 | 寿光众新晶体材料有限公司 | 一种羟基氧化铝浆料的制备方法 |
EP4008751B1 (fr) * | 2020-12-02 | 2023-09-06 | SHPP Global Technologies B.V. | Composition, son procédé de fabrication et articles préparés à partir de la composition |
CN113233483A (zh) * | 2021-05-22 | 2021-08-10 | 邹平恒嘉新材料科技有限公司 | 一种纳米级勃姆石材料制备方法 |
CN114180606B (zh) * | 2021-12-08 | 2023-07-28 | 安徽壹石通材料科技股份有限公司 | 一种掺杂勃姆石二维形貌控制方法 |
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